Booster Kit Installation Manual
Contents
1. 49 0 8106 99 79 689 www picoamps de e mail info picoamps de Mount Spring to the Brush Holder pico amps Step 1 Insert the spring at the spring holder and the angle bracket Step 2 Adjust the play of the Bowden cable such that the full rotation range Is used by pulling the finger lever Note The zero force of the spring can be increased when changing the orientation of the spring holder as shown Through the asymmetry of the spring holder the spring will receive an additional pre load of 5 mm or ca 14N 5 mm Important Make sure that the brush plate is smoothly pulled back to zero position by the spring picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 9979 689 www picoamps de e mail info picoamps de Final Mounting pico amps Connect the power cables to the brush plate and mount the brush plate cover Bend the power cables such that the rotation of the brush plate will not be hindered Connect the thermal switch Make sure that motor transmission and rear wheel are freely rotatable One should hear only the usual grinding sound of the brushes Otherwise remove the brush plate to find out the reason Connect the main power plug ready to go picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 99 79 689 www picoamps de e mail info picoamps de2. brush plate Step 4 Dismount brush plate 4 x M4 Inbus screws picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 99 79 689 www picoamps de e mail info picoamps de Mounting of Booster Kit al Mounting of Finger Lever and Bowden Cable Finger Lever mount finger lever to the left side of the hanlde bar We recommend monunt the lever for the booster underneath the lever for the rear brake Warning the brake lever the must not be blocked or obstructed by the finger lever for the booster Bowden Cable The Bowden cable should be placed under the tank covering avoiding sharp bends and giving sufficient play for moving the handle bar picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 9979 689 www picoamps de e mail info picoamps de pico amps Mounting of Booster Kt Mounting of angled bracket and frame washer pico amps Step1 Dismount bearer from frame remove screws on both ends Step 2 On the left side place angled bracket between bearer and frame 6 Step 3 On the right side place frame washer between bearer and frame Step 4 Mount bearer to frame firmly tighten screws on both ends Step 5 Place Bowden cable into the angled bracket between nut and setscrew picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 9979 689 www picoa
3. 9 79 689 www picoamps de e mail info picoamps de Mounting of the brush plate mounting bolts pico amps Step 1 Insert the bolts into the nuts and fix with medium force using a 2 5 mm hex wrench and a 4 mm socket wrench Step 2 Place the brush plate in the opening of the motor housing of the without inserting cable and spring Step 3 on each bolt slide an adjustment washer and a drused washer and place the bolts into the prepared M4 screw holes and tighten with medium force Wait for approximately 1 hour for the glue to harden Unscrew the nuts When removing the nuts the bolts have to remain tightly in the housing If one of the bolts is loose the procedure has to be repeated Optionally use a stronger version of LOCTITE picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 99 79 689 www picoamps de e mail info picoamps de Mounting Bowden cable on prush plate pico amps step 1 Dismount the brush plate again the bolts have to stay in the motor housing Step 2 Before mounting the brush plate insert the cable into the cable holder 24 sprocket pulley 30 sprocket pulley e Bowden ai cable Note Depending on the used belt pulley the ea position of the motor in the frame is e different Therefore the string holder LP provides two different fitting holes to B A fix the cable O The rear position correspo
4. mps de e mail info picoamps de Preparation of the brush plate Step 1 pico amps Note the stiffener plate is already mounted on Heavy Duty Kit or Tuning Kit Fit the delivered stiffener plate onto the tubes and shift tightly against the brush plate Note One of the eight apertures in the stiffener plate is enlarged to provide space for the thermal switch Therefore the stiffener plate can only be mounted in one orientation If the thermal switch is mounted in the wrong position this has to be corrected in step 2 Enlarged opening for thermal switch picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 99 79 689 www picoamps de e mail info picoamps de Note the stiffener plate is already mounted on Heavy Duty Kit or Tuning Kit On some brush plates the thermal switch is fixed to the x outer side of the adjacent brush tube so that the stiffener plate will not fit In this case the thermal switch has to be carefully removed using a thin blade The thermal switch has then to be fixed onto the inner side of the correct brush tube as shown To fix the switch use a two component epoxy glue with a temperature stability of at least 150 C picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 99 79 689 www picoamps de e mail info picoamps de Preparation of the brush plate S pico amps Note the stiffener plate is alread
5. nds to the 24 sprocket pulley and the position corresponds to the 30 sprocket pulley Wo T Step 3 Place the brush plate with mounted Bowden cable into the motor housing picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 99 79 689 www picoamps de e mail info picoamps de Mounting of the complete Brush Plate pico amps Step1 Place one drused washer in each oval hole TAKE CARE OF THE CORRECT ORIENTATION see also the following safety warning Step 2 Tighten the nuts with medium force Note The adjustment washers are not used for the final mounting of the brush plate Mount the drused washers only Due to the removed adjustment washers the brush plate should have an axial play of 0 5 mm at all four nuts when the nuts are Important Check that the brush plate does freely rotatate with low friction Dispense some grease on the drused washer to reduce the friction for the nut picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 99 79 689 www picoamps de e mail info picoamps de Safety Warning Orientation of the drused washers pa Bi pico amps Important Attention The drused washers have to With the wrong orientation be inserted in the correct of the drused washers the orientation as shown motor will be destroyed picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax
6. pico amps For LEMCO brushed DC motors Issue date 22 02 2011 picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 99 79 689 www picoamps de e mail info picoamps de 4 x drused washer frame washer picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 99 79 689 www picoamps de e mail info picoamps de Booster Restriction of Usage pico amps Important Note Only use with correct sense of rotation The Booster Kit is designed for motors that spin clockwise when looking onto the brush plate and must only be used with those The instructions in this manual are therefore valid for motors with clockwise rotation In principle it is possible to also use it with motors that spin counter clockwise which requires some modifications of the Booster Kit Please contact picoamps in this case If the unmodified Booster Kit is used on motors with wrong sense of rotation there is a risk that the motor will be permanently damaged picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 99 79 689 www picoamps de e mail info picoamps de Mounting of Booster Kit Dismounting of brush plate pico amps Step 1 Disconnect main power plug from battery Step 2 Disconnect plug of temperature switch Step 3 Disconnect power cables and remove cover of
7. y mounted on Heavy Duty Kit or Tuning Kit Place the delivered rubber ring directly behind the stiffener plate so that the stiffener plate will not slip from the brush tubes picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 9979 689 www picoamps de e mail info picoamps de Mounting of Spring and Cable Holder pico amps The delivered spring and cable holder are mounted to the copper star on the side facing toward the motor housing as shown below Note that a cooling plate is placed between spring holder and copper star Cable Holder eg 00000 00000 Spring Holder bent edge facing down picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 9979 689 www picoamps de e mail info picoamps de Dispensing the glue to fix the brush plate mounting bolts pico amps Clean and remove grease and oil from the four M4 mounting holes for the brush plate in the motor housing before dispensing glue To fix the bolts use LOCTITE medium or strong Dispense the glue into the M4 holes before mounting the bolts using a suitable tool e g thin Stick There must be no glue on the motor housing near the thread holes Attention GN Remove excess glue on the housing surface Otherwise the booster will not work picoamps GmbH Ingelsberger Weg 50 phone 49 0 8106 99 79 688 D 85604 Zorneding fax 49 0 8106 9
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